Operations After Installing Engine

TRANSMISSION LINKAGE ADJUSTMENTS

Linkage Adjustment, Manual Trans.:

Manual Transmission:

1. Adjust reversing lock clamp:
- Engage 1st gear.
- Adjust clearance between clamp and gear lever. The clearance must be 0.5-1.5 mm (0.020-0.059 in), measured with a feeler gauge.
- Tighten fastening screws.
2. Also check clearance in 2nd gear.
3. Install rubber gaiter (boot).

Linkage Adjustment, Automatic Trans.:

Automatic Transmissions:

1. Check-adjust gear selector.
step 1. Check that clearance from position D to stop = position 2 to stop.
step 2. Adjust gear selector rod length if necessary.
- Rough adjustment, use adjuster at rear of selector rod.
- Fine adjustment, use sleeve (max. visible thread = 35 mm (1.4 in).

NOTE: Extending rod decreases position D clearance and increases position 2 clearance.

2. After adjustment, move selector lever to position 1 and then to P. Repeat the check according to step 1.

ENGINE CHECKS & ADJUSTMENTS:

Engine Fluid Levels:

1. Fill engine with oil and coolant.
- Engine oil volume 3.85 liters (4.1 US qts) (incl. oil filter).
- The cooling system holds 9.5 liters (10.0 US qts) (manual transmission) and 9.3 liters (9.8 US qts) (automatic transmission). Set heater control to MAX when adding coolant.

2. Vehicles with automatic transmission, check oil level, top up if necessary.

NOTE: The engine must be running and the gear selector must be in position N or P.

Check For Fluid Leakage:

3. Run engine to operating temperature:
- Check for oil and coolant leakages.
- Refill coolant as required.

Throttle Control Linkage Adjustments:

Throttle Cable Adjustment:

1. Adjust throttle cable:
- Cable should be stretched but should not influence pulley position.
- Depress accelerator pedal to floor and check that throttle control pulley touches full throttle stop.

Kick-Down Cable Adjustment:

2. Check/adjust kick-down cable (automatic transmission):
- Depress accelerator pedal to floor. Do not move control by hand as the adjustment may be incorrect.
- In kick-down position, distance between adjusting sleeve and cable stop should be: 50.4-52.6 mm (1.984-2.071 in).

Final Engine Checks

Check & Adjust Timing & CO:

1. Check/adjust:
- ignition timing
- idle speed and CO.

2. After driving approx. 1000 km (600 miles):
- Tension timing belt.
- If valve system has been repaired, valve clearance should be checked/adjusted.